US4226086A - Automatic restart control for a power plant boiler - Google Patents

Automatic restart control for a power plant boiler Download PDF

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Publication number
US4226086A
US4226086A US06/040,782 US4078279A US4226086A US 4226086 A US4226086 A US 4226086A US 4078279 A US4078279 A US 4078279A US 4226086 A US4226086 A US 4226086A
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United States
Prior art keywords
boiler
turbine
steam
pressure
temperature
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Expired - Lifetime
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US06/040,782
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English (en)
Inventor
Morton H. Binstock
Robert C. Lehmer
Steven J. Johnson
John J. Topolosky
Thomas E. Smith
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CBS Corp
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Westinghouse Electric Corp
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Priority to US06/040,782 priority Critical patent/US4226086A/en
Priority to JP6658180A priority patent/JPS55156205A/ja
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Publication of US4226086A publication Critical patent/US4226086A/en
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01K—STEAM ENGINE PLANTS; STEAM ACCUMULATORS; ENGINE PLANTS NOT OTHERWISE PROVIDED FOR; ENGINES USING SPECIAL WORKING FLUIDS OR CYCLES
    • F01K13/00—General layout or general methods of operation of complete plants
    • F01K13/02—Controlling, e.g. stopping or starting

Definitions

  • the present invention relates to boiler controls and more particularly to automatic controls for restarting a hot boiler with temperature matching between the boiler and turbine.
  • a hot plant restart may occur right after an unplanned plant shutdown trip, or after an overnight or weekend shutdown.
  • the turbine metal temperature is normally higher than that of the boiler steam because the boiler cools faster than the turbine. This is due both to the quicker cooldown rate of the boiler and the inability of the boiler to produce rated steam temperature at low load.
  • a hot restart control is provided for a boiler in a power plant having a steam turbine with steam admission valve means for turbine steam flow and bypass valve means for bypass steam from the boiler to the plant condenser.
  • the control includes means for generating a turbine metal temperature signal, means for generating a boiler steam temperature signal, and means for generating a boiler throttle pressure signal.
  • Computer means are provided for generating a target boiler load and pressure in response to the turbine metal temperature and throttle pressure.
  • the boiler combustion is controlled to increase the boiler firing rate after a boiler shutdown with the turbine admission valve means closed so as to increase the boiler steam pressure and temperature with continuously adequate boiler steam flow.
  • Means are provided for operating the bypass valve means to control the steam throttle pressure to a pressure setpoint based on the target pressure with the turbine admission valves remaining closed.
  • the boiler firing rate is held.
  • the opening movement of the turbine admission valves is then controlled to transfer steam flow to the turbine from the bypass valve means so as to accelerate, synchronize and load the turbine as the bypass valve operating means provides steam throttle pressure control with closing bypass valve movement.
  • FIG. 1 shows a schematic diagram of a power plant controlled in accordance with the principles of the invention
  • FIG. 2 shows a more detailed diagram of the way in which hot restart control is provided for the power plant
  • FIGS. 3A-3C show detailed functional diagrams of the hot start control
  • FIG. 4 shows a typical boiler load-temperature characteristic.
  • FIG. 1 an electric power plant 10 having a boiler 12 which supplies steam to drive a turbine 14 and electric generator 16.
  • a turbine bypass valve system 18 is in this example shown to be the classical European type. It includes a high pressure bypass valve 20 and a low pressure bypass valve 22 which are automatically operated by controls 24 and 26 in accordance with the invention.
  • Fast plant restart is enabled by the bypass system from its ability to produce an apparent boiler load and/or a reduced operating pressure. For example, as shown in FIG. 4 a boiler operating at 80% load would produce 1,000° F. superheat steam and perhaps a turbine temperature of 980° F. The load drops to zero if a plant trip occurs. It is desirable to bring the boiler unit on a hot restart back up to 80% load as quickly as possible. There is no turbine heating problem since the turbine is already at a high load operating temperature of 980° F. The boiler heating problem results from the inability of a standard boiler to produce 1,000° F. steam during the low load start-up procedure.
  • a feedpump 28 transfers water from a condenser 30 to the boiler 12 where fuel is burned to convert the water to steam.
  • a superheater 32 heats the steam and controls its outlet temperature to 1,000° F. whenever possible.
  • Turbine throttle/governor valves 34 are controlled to regulate the amount of steam flow into the high pressure turbine section which extracts useful work from the steam.
  • the high pressure turbine exhaust steam is reheated by reheater 35 to 1,000° F. if possible, and the reheated steam passes through a turbine intercept valve 36 (normally open except during turbine start-up), through the turbine intermediate and low pressure sections which extract additional useful work from the steam and then back to the condenser 30 to start the cycle again.
  • bypass valves 20 and 22 are operated to produce turbine/boiler temperature matching prior to turbine startup.
  • the plant operator uses controls to provide prior art bypass valve operation for a hot restart as follows:
  • the boiler 12 is loaded and steam flows through the normal boiler circuits, the superheater 32, and the reheater 35, but the turbine valves 34 and 36 are closed so that boiler steam flows to the condenser 30, through the bypass valves 20 and 22 and not through the turbine 14.
  • the boiler 12 therefore acts as though it is operating a turbine under load and produces the required superheat and reheat steam temperatures. Steam pressure is controlled during boiler restart by interaction of the boiler firing rate and the position of the bypass valve 20.
  • the present invention includes features which automate and improve the operation of a hot restart bypass system.
  • the plant controls function in accordance with the invention to provide bypass valve system operation during a hot plant restart as follows:
  • the best pressure and load combination is computed using measured data and the boiler characteristic curve to allow a temperature match.
  • the computed pressure and load values are preferably used as a target rather than an absolute value, and the target is adaptively modified as actual plant conditions change.
  • Fuel is controllably added to the boiler since too high a fuel input without adequate steam flow overheats the superheater and the reheater.
  • the bypass valves are controlled to control steam pressure. As steam pressure increases, steam flow increases and additional fuel can be added as the superheater and reheaters are somewhat protected. In turn, fuel can be increased even more and the process continues under automatic control until the computed target values of load, pressure and temperature are reached.
  • the present invention preferably further includes adaptive controls which determine when the target load is reached and then readjusts the fuel through a fine tuning mechanism to shift the load in the correct direction and assure a temperature match.
  • a temperature match light is provided as an indicator for the operator.
  • bypass valves are automatically closed in a synchronized manner. For every additional unit of steam flow to the turbine 14, one less unit of steam goes through the bypass system. In other words, steam flow is smoothly diverted from the bypass system to the turbine 14.
  • the operator is relieved of the requirement to operate the plant during a hot plant restart by means of an automatic control which provides needed control functions during restart operation.
  • the boiler parameters needed to match turbine and boiler temperatures are computed, the boiler is fired to achieve a steam temperature which matches the turbine temperature.
  • the steam pressure is regulated and the boiler is protected from overfiring during the temperature matching restart.
  • the superheater and reheater steam temperatures are regulated and the proper boiler load is maintained by pressure regulation after a temperature match and as the turbine is being accelerated to synchronism and loaded.
  • the power plant 10 is controlled by a plant unit master 40 which coordinates the operation of boiler combustion controls 42 and a turbine control 44.
  • a hot restart control 46 is initiated when the operator presses a Temperature Match Pushbutton 48 for a hot restart. Thereafter, the control 46 operates the bypass valves 20 and 22, superheater and reheater controls 50, 52 and the boiler combustion controls 42.
  • the restart control 46 is described herein as being embodied with analog hardware, but other variations can be employed including digital computer implementations. Individual analog functional blocks are embodied with the use of conventional commercially available control circuit cards.
  • boiler load control during a hot restart is initiated by closure of relay contact 54 which then couples a target computer 56 to plant unit master 40.
  • the load and pressure computer 56 receives a throttle pressure signal 58 and a turbine metal temperature signal 60 and provides an output for the required target boiler load. To prevent process interaction, the output from the computer 56 becomes fixed when the contact 54 selecting a temperature match is closed.
  • the computer 56 contains in its memory a temperature vs. load relationship like that shown in FIG. 4. The exact curve relationship is determined for each boiler based either on manufacturer's information or empirical measurements.
  • the computer 56 outputs a demand of 37.5% fuel to the plant unit master 40.
  • a firing rate high limiter 62 limits the 37.5% demand from the plant unit master 40 and the computer 56 to a safe warm-up value of 3-7% in response to a limit amplifier 64 having a bias input 65. Additional fuel is supplied to the boiler 12 as steam flow is established since a steam flow signal 59 is applied to the amplifier 64 causing the fuel demand limit to be raised as steam flow increases. As an alternate, hot boiler gas exit temperature 66, if available, can be used to limit the boiler firing.
  • the firing rate limiter 62 plays an important role due to its process adaptiveness. To prevent damage to the boiler piping, it is imperative that the boiler not be fired too much when there is inadequate steam flow. On the other hand, to achieve a quick restart it is important to fire the boiler as hard as possible.
  • the firing rate limiter allows maximum firing with boiler protection by making use of relevant process feedback.
  • Target load is achieved when the 37.5% target is applied to and implemented by amplifier 68 as boiler fuel demand.
  • the target load value may not produce either an exact match between turbine metal temperature and boiler steam or even the actual target loading since, for example, the fuel BTU may have changed since initial control system calibration. It is thus preferred that means be provided to fine tune the boiler load to achieve a true temperature match.
  • Target detector 70 determines when the target load value is established, i.e. the input and output values of the firing rate limiter 62 are equal.
  • the target detector 70 closes relay contact 72 to activate a fine trim temperature match controller 74.
  • the actual steam temperature and turbine metal temperature are compared by the controller 74 and the resultant output signal acts through a target temperature trim amplifier 68 to fine trim fuel demand to the boiler 12 so as to adjust the load.
  • Load changes as shown in FIG. 4, in turn change the steam temperature to obtain a true match with the turbine metal temperature.
  • a temperature match detector 76 compares the two temperature signals and provides the operator with a temperature match light signal when the turbine metal and steam temperatures are equal. The operator is then free to roll and load the turbine.
  • FIG. 3B there is shown a pressure control portion 80 of the hot restart control.
  • the computer 56 uses information on the plant current status and the FIG. 4 curve to select a target load as previously described.
  • a pressure setpoint which should allow a temperature match at the target load is selected by the computer 56.
  • the load is controlled by regulating the amount of fuel supplied to the boiler.
  • the boiler outlet pressure is controlled by a valve, specifically the high pressure bypass valve 20. This control strategy allows control decoupling between load and pressure and also allows for a decoupled or noninteractive pressure control when load is transferred from the bypass system 18 to the turbine 14.
  • the pressure control portion 80 begins to function and a throttle pressure programmer 82 gradually ramps the throttle pressure setpoint from the current value to the required value.
  • a pressure controller 84 acting through a closed relay contact 86, compares the pressure setpoint against the actual pressure from sensor 88 and regulates the position of the high pressure bypass valve 20 through a conventional valve positioner. Too low a pressure results in closing valve movement.
  • Steam flow programmer 90 and low limiter 92 respond to a throttle pressured signal to limit bypass valve movement and protect the boiler 12 from too low a steam flow. It is important, as previously described, that adequate steam flow be maintained to prevent overheating the boiler 12.
  • the steam flow programmer is characterized to generate a safe limit on bypass valve position as a function of throttle pressure.
  • the low limiter allows the controller to close the valve somewhat, i.e. enough to cause a gradual pressure buildup, but not so much as to cause an unnecessary faster pressure buildup while jeopardizing steam flow.
  • the pressure controller 84 assures a smooth transfer of load from the bypass system 18 to the turbine 14. The load transfer is decoupled from the boiler load control.
  • the IP bypass valve is inversely slaved to the turbine IP intercept valve by inverse position computer 94 and closes as the turbine IV valve opens.
  • the governor and intercept valves are coupled together so that opening the governor valve also opens the intercept valve.
  • the IP bypass valve is controlled to close in proportion to the IV valve opening thereby to maintain total boiler load resistance constant and thereby to assure a controlled steam flow transfer from the condenser to the IP turbine. Any error in total boiler load resistance results in a throttle pressure error which is compensated by the HP bypass pressure control. With system decoupling, the turbine controls are free to regulate speed or load without regard to throttle pressure control.
  • FIG. 3C shows a control 91 used to match reheat temperature to intermediate pressure temperature.
  • Measured intermediate pressure metal temperature is the setpoint for reheat temperature.
  • the setpoint is wired through a relay contact 93 to the boiler control which controls reheat temperature to the new setpoint through existing controls such as tilts, sprays, pass dampers, etc.
  • a light is operated by a temperature error detector 95 when the reheat temperature matches the turbine metal temperature.
  • Control of reheat temperature is in accordance with the controls in FIG. 3C. Depending on which loop (superheat or reheat) increases temperature faster, the roles of the superheater and the reheater may be switched.
  • the high pressure turbine metal temperature and superheat temperature become the intermediate pressure turbine metal temperature and reheat temperature on a sole reversal. All other functions and operation are the same. In this case, the controls of FIG. 3C would then control HP turbine metal temperature to superheat temperature.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Control Of Steam Boilers And Waste-Gas Boilers (AREA)
US06/040,782 1979-05-21 1979-05-21 Automatic restart control for a power plant boiler Expired - Lifetime US4226086A (en)

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US06/040,782 US4226086A (en) 1979-05-21 1979-05-21 Automatic restart control for a power plant boiler
JP6658180A JPS55156205A (en) 1979-05-21 1980-05-21 Automatic restarting controller for boiler of power plant

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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4584836A (en) * 1985-01-29 1986-04-29 Westinghouse Electric Corp. Steam turbine restart temperature maintenance system and method
US4651532A (en) * 1985-04-12 1987-03-24 Hitachi, Ltd. Method of warming up a reheat turbine
US5172553A (en) * 1992-01-21 1992-12-22 Westinghouse Electric Corp. Convective, temperature-equalizing system for minimizing cover-to-base turbine casing temperature differentials
US5410883A (en) * 1991-09-05 1995-05-02 Hitachi, Ltd. Control system for plant
US6647727B2 (en) * 2001-07-31 2003-11-18 Alstom (Switzerland) Ltd. Method for controlling a low-pressure bypass system
US20060168963A1 (en) * 2005-01-24 2006-08-03 Honda Motor Co., Ltd. Rankine cycle system
US20060201154A1 (en) * 2005-03-11 2006-09-14 Honda Motor Co., Ltd. Rankine cycle system
EP1744020A1 (de) * 2005-07-14 2007-01-17 Siemens Aktiengesellschaft Verfahren zum Starten einer Dampfturbinenanlage
EP2143891A2 (en) * 2008-07-10 2010-01-13 Ansaldo Energia S.P.A. A device and method for controlling the pressure of a steam turbine of a combined cycle plant and a bypass system thereof
US20110167823A1 (en) * 2008-07-25 2011-07-14 Jurgen Berger Steam circuit process device and method for controlling the same
US20120233978A1 (en) * 2011-03-18 2012-09-20 Rahul Chillar Apparatus for starting up combined cycle power systems and method for assembling same
US20150211387A1 (en) * 2014-01-27 2015-07-30 Kabushiki Kaisha Toshiba Steam turbine pipe
WO2015197238A1 (de) * 2014-06-23 2015-12-30 Siemens Aktiengesellschaft Verfahren zum anfahren eines dampfturbinensystems
US9328633B2 (en) 2012-06-04 2016-05-03 General Electric Company Control of steam temperature in combined cycle power plant
US20180142579A1 (en) * 2015-04-24 2018-05-24 Nuovo Pignone Tecnologie Srl Compressor driven by orc waste heat recovery unit and control method

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0646082B2 (ja) * 1984-07-16 1994-06-15 バブコツク日立株式会社 ボイラ装置
JPH0665921B2 (ja) * 1984-07-16 1994-08-24 バブコツク日立株式会社 ボイラ起動制御装置
EP3460202A1 (de) * 2017-09-22 2019-03-27 Siemens Aktiengesellschaft Dampfturbinenregelung

Citations (5)

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US2900792A (en) * 1955-06-04 1959-08-25 Sulzer Ag Steam power plant having a forced flow steam generator
US2902831A (en) * 1958-08-22 1959-09-08 Gen Electric Governing system for reheat steam turbine powerplant
US3226932A (en) * 1960-06-07 1966-01-04 Gilbert Associates Devices for improving operating flexibility of steam-electric generating plants
US3882680A (en) * 1972-04-18 1975-05-13 Babcock & Wilcox Co By-pass system
US4091450A (en) * 1976-01-28 1978-05-23 Bbc Brown Boveri & Company Limited Method and apparatus for set point control for steam temperatures for start-up of the turbine and steam generator in unit power plants

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2900792A (en) * 1955-06-04 1959-08-25 Sulzer Ag Steam power plant having a forced flow steam generator
US2902831A (en) * 1958-08-22 1959-09-08 Gen Electric Governing system for reheat steam turbine powerplant
US3226932A (en) * 1960-06-07 1966-01-04 Gilbert Associates Devices for improving operating flexibility of steam-electric generating plants
US3882680A (en) * 1972-04-18 1975-05-13 Babcock & Wilcox Co By-pass system
US4091450A (en) * 1976-01-28 1978-05-23 Bbc Brown Boveri & Company Limited Method and apparatus for set point control for steam temperatures for start-up of the turbine and steam generator in unit power plants

Cited By (27)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4584836A (en) * 1985-01-29 1986-04-29 Westinghouse Electric Corp. Steam turbine restart temperature maintenance system and method
US4651532A (en) * 1985-04-12 1987-03-24 Hitachi, Ltd. Method of warming up a reheat turbine
AU576076B2 (en) * 1985-04-12 1988-08-11 Hitachi Limited Steam turbine warm-up procedure
US5410883A (en) * 1991-09-05 1995-05-02 Hitachi, Ltd. Control system for plant
US5172553A (en) * 1992-01-21 1992-12-22 Westinghouse Electric Corp. Convective, temperature-equalizing system for minimizing cover-to-base turbine casing temperature differentials
US6647727B2 (en) * 2001-07-31 2003-11-18 Alstom (Switzerland) Ltd. Method for controlling a low-pressure bypass system
US20060168963A1 (en) * 2005-01-24 2006-08-03 Honda Motor Co., Ltd. Rankine cycle system
US20060201154A1 (en) * 2005-03-11 2006-09-14 Honda Motor Co., Ltd. Rankine cycle system
EP1744020A1 (de) * 2005-07-14 2007-01-17 Siemens Aktiengesellschaft Verfahren zum Starten einer Dampfturbinenanlage
WO2007006617A2 (de) * 2005-07-14 2007-01-18 Siemens Aktiengesellschaft Verfahren zum starten einer dampfturbinenanlage
WO2007006617A3 (de) * 2005-07-14 2008-06-26 Siemens Ag Verfahren zum starten einer dampfturbinenanlage
US20090126365A1 (en) * 2005-07-14 2009-05-21 Edwin Gobrecht Method for starting a steam turbine installation
US7805941B2 (en) * 2005-07-14 2010-10-05 Siemens Aktiengesellschaft Method for starting a steam turbine installation
EP2143891A2 (en) * 2008-07-10 2010-01-13 Ansaldo Energia S.P.A. A device and method for controlling the pressure of a steam turbine of a combined cycle plant and a bypass system thereof
EP2143891A3 (en) * 2008-07-10 2011-01-26 Ansaldo Energia S.P.A. A device and method for controlling the pressure of a steam turbine of a combined cycle plant and a bypass system thereof
US20110167823A1 (en) * 2008-07-25 2011-07-14 Jurgen Berger Steam circuit process device and method for controlling the same
US20120233978A1 (en) * 2011-03-18 2012-09-20 Rahul Chillar Apparatus for starting up combined cycle power systems and method for assembling same
CN102691531A (zh) * 2011-03-18 2012-09-26 通用电气公司 用于启动联合循环动力系统的设备及其组装方法
US8347598B2 (en) * 2011-03-18 2013-01-08 General Electric Company Apparatus for starting up combined cycle power systems and method for assembling same
US9328633B2 (en) 2012-06-04 2016-05-03 General Electric Company Control of steam temperature in combined cycle power plant
US20150211387A1 (en) * 2014-01-27 2015-07-30 Kabushiki Kaisha Toshiba Steam turbine pipe
WO2015197238A1 (de) * 2014-06-23 2015-12-30 Siemens Aktiengesellschaft Verfahren zum anfahren eines dampfturbinensystems
CN106460566A (zh) * 2014-06-23 2017-02-22 西门子公司 用于启动蒸汽轮机系统的方法
CN106460566B (zh) * 2014-06-23 2018-09-18 西门子公司 用于启动蒸汽轮机系统的方法
US10385733B2 (en) 2014-06-23 2019-08-20 Siemens Aktiengesellschaft Method for starting a steam turbine system
US20180142579A1 (en) * 2015-04-24 2018-05-24 Nuovo Pignone Tecnologie Srl Compressor driven by orc waste heat recovery unit and control method
US10975733B2 (en) * 2015-04-24 2021-04-13 Nuovo Pignone Srl Compressor driven by ORC waste heat recovery unit and control method

Also Published As

Publication number Publication date
JPS6123366B2 (es) 1986-06-05
JPS55156205A (en) 1980-12-05

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